tokamak cooling water systems (tcws) design and ... to a supporting welding procedure specification...

TCWS Design and Centralized procurement for ITER Piping Information Day

ITER Headquarters, October 7th 2014

© 2014, ITER Organization

Page 1IDM UID: Q75AVH v1.1

Tokamak Cooling Water Systems (TCWS) Design and Centralized

Procurement for ITER Piping

14:00 / 16:30 : Conference Part 2





Info Day Agenda10:00 / 13:00 : Conference Part 1

1 - Introduction and general presentation

2 - General presentation of Tokamak Cooling Water Systems

3 - General presentation of other systems in centralized procurement


4 - Quality Assurance requirements –14:00 / 14:10

5 - TCWS Procurement general strategy / program – 14:10 / 14:40

6 - Focus on Design contracts – 14:40 / 15:00

7 - Focus on Procurement contracts - 15:00/ 15:15

8 - US DA Procurement program - 15:15 / 15:30

9 - Questions / Answers - 15:30 / 16:00

10 - Conclusion – 16:00 / 16:15

16:30 / 17:30 : Site visit
















10 - Conclusion – 16:00 / 16:15

16:30 / 17:30 : Site visit







4 – Quality Assurance requirements

Mark Gardner - IO/SQS/QAD Quality Assurance Engineer





� ITER QA Program

• Quality Plan• Manufacturing and Inspection Plan• Deviations and Non Conformances• Release Notes• Welding Requirements

� Quality Classification Determination

� Specific requirements from ESP and ESPN French regulations

Outlines :

4 - Quality Assurance requirements





Quality Plan (reference ITER_D_22MFMW)

� Each Supplier or Subcontractor providing equipment or servicesto the ITER Organization must provide a dedicated Quality Plan.

� A Quality Plan covers the whole scope of the contract anddescribes the operational quality system (based on ISO 9001 orequivalent) to ensure that:� Contract requirements will be met� Evidence of such compliance is maintained

� Work shall not start until the relevant Quality Plan has beenaccepted by ITER.






Quality Plan (reference ITER_D_22MFMW)

� The Quality Plan is contract specific and shall identify:

• the specific allocation of resources, duties, responsibilities andauthority;

• details of all suppliers/subcontractors and how interfaces will bemanaged;

• the specific procedures, methods and work instructions to beapplied;

• the specific methods of communication, both formal and informal,to be established between working groups.

� Much of the generic documentation needed to prepare the Quality Planwill normally already exist as part of the Supplier/Subcontractor’squality management system and supporting procedures. The QualityPlan need only refers to this documentation and shows how it is to beapplied to the particular contract.






Manufacturing and Inspection Plan (reference ITER_D_22MDZD)

� Each Supplier and sub-contractor shall supply the DA with a MIPlisting the sequence of manufacturing operations encompassing thewhole scope of the contract (review of drawings, verification ofmaterials, manufacture, inspection and test to delivery…).

� MIP allows supplier, DA and IO to mention control points (NP, HP,WP…).






Manufacturing and Inspection Plan






Deviations and Non Conformances (reference ITER_D_22F53X)

� Deviation: A planned alternative to a specified requirement.

When a deviation to IO specifications is anticipated theSupplier/Contractor shall discuss it with the IO/DA responsible officer asappropriate for that ITER work activity. If the proposal is consideredbeneficial, the Deviation Request shall be sent to IO for approval.

� Non-Conformance: Any condition, which does not comply with a

specified requirement.

When a non-conformance is identified the Supplier/Contractor shall:• Identify, and segregate when practical, the non-conforming item• stop any further work on the item until a decision is made• record and report the occurrence by raising a Non-conformance

Report• Minor Non-conformances are sent to IO for information• Major Non-conformances are sent to IO for approval






Release Notes (reference ITER_D_22F52F)

� The release note must be signed before equipment is deliveredto the ITER site.

� It specifies what equipment/components are being delivered.

� It lists the documents supplied with the equipment.






� Systems, structures and components are classified into one of the fourquality classes and the following shall be noted:

• All SIC-1 systems and component parts shall be Quality Class 1

• SIC-2 systems and component parts can be Quality Class 1 or 2

• Commercial Grade or Proprietary Items that are purchased using a

manufacturer’s catalogue or other commercially available

documentation that have been assessed as Quality Class 1, 2 or 3,

need only be supplied with a manufacturer’s “Certificate of

Conformity”.

• Modified commercial or proprietary items shall conform to ITER

Procurement Quality Requirements (ITER_D_22MFG4) .

Quality Classification Determination






Welding Requirements

� Weld Plan

• Before fabrication can commence the supplier shall prepare for

approval a weld plan.

• The weld plan is a drawing which cross references each welded

joint to a supporting Welding Procedure Specification (WPS).

� Welder and Operator Qualification

• Welder qualification shall be in accordance with EN 287-1, ISO

9606 or equivalent standards agreed in advance. For welding

operators ISO 1418 shall be used.

• Other standards may be approved by ITER on submission of

documentation detailing the equivalence between the proposed

standards and the standards quoted herein.






� Welding Procedure Qualification Record:

• The Welding Procedure Qualification Record (WPQR) is used to

record all the relevant data from the welding of test pieces in WPS

qualification.

• The WPQR is the qualification of the WPS and provides proof that

the defined welding process will achieve a weld of acceptable

quality. The welding and testing of this must be witnessed by an

ITER recognised Independent Inspection Authority.

• All welding data and results from the required non-destructive and

destructive testing shall be documented using a WPQR endorsed

by the witnessing Independent Inspection Authority.

� Inspections• All Quality Class 1 welds will require 100 percent Visual, Surface,

and Volumetric inspections.

Welding Requirements

















10 - Conclusion – 16:00 / 16:15

16:30 / 17:30 : Site visit







5 – TCWS Procurement general strategy

/ program

Antoine CALMES –IO/ADM/GEA/PCD/IPS – TCWS Procurement Officer





5 - TCWS&CP Procurement general strategy/program

Outlines :

� 5.1 - IO In-Cash Procurement rules

� 5.2 - TCWS General Contractual Strategy

� 5.3 - TCWS Contractual Strategy for Design

� 5.4 - TCWS Contractual Strategy for Procurement

� 5.5 - Centralized Piping Opportunity for Procurement

� 5.6 - TCWS Contractual Strategy for Notified Body

� 5.7 - TCWS Contracts Mapping and Conflict of Interest

� 5.8 - TCWS and Centralized Piping Contracting Program Overview





5.1 - IO In-Cash Procurement rules :

� Principles :

• IO recognizes the basic principles of competition, fair andequal treatment of Tenderers

• These principles shall ensure that the IO can obtain the bestvalue for money by soliciting participation of a number ofqualified firms.

� Procurement and Contracts Division (PCD) :

• PCD primary objective and responsibility is to protect the IO’sinterest while procuring supplies, services, and works to meetits organizational requirements.

• PCD in charge of the management of tendering processesand then administrating the contracts






� Two methods for the award criteria are implemented:

• Lowest-price technically compliant

� The contract is awarded to the tenderer meeting all requirements and offering the lowest price.

� Technical compliancy usually evaluated based on a Compliance Matrix to be filled-in by the Tenderers

• Best value for money

� The contract is awarded to the tender with the best price-quality, taking into account criteria justified by the scope of the contract.








� Call for tender process ⇒ A 3 phased process

• Stage 1 - Call for Nomination (minimum 1 month) :

� IO formally invites the DAs to nominate potential suppliers.

• Stage 2 - Pre-Qualification (PQ) (minimum 1.5 months) :

� Ensure that offers are sought only from suppliers who have thefinancial capabilities as well as requested skills, equipmentand experience to perform works or services as described inthe technical summary (and later in the technicalspecifications).

� The PQ form includes :• Questionnaire with Pre-Qualification criteria (pass/ fail)• Technical Summary of the scope • Administrative forms







� Stage 3 - Call for Tender (CFT) (minimum 3 months) :

• The Call for Tender is used to obtain proposals from identified pre-qualified

suppliers.

• Call for Tender content : � Cover letter with the deadline for submission of offers � Annex 1: Instructions To Tenderers

� Annex 2: Technical Specifications (including Quality, Management, etc.)

� Annex 3: Draft Contract

• Instructions To Tenderers content :

� Schedule of the CFT

� Formal forms required to be filled-in (ex. Compliance Matrix)� Tender required content : Technical, Management and Financial parts

� Award method

� Evaluation criteria


IMPORTANT: Clarifications are always possible until a few weeks

before the due date of the offers.






� Evaluation process

• Evaluation Committee is composed of :

� IO Representatives from Technical Directorates and PCD� Experts if needed

All members have declared a non-conflict of interest and confidentiality commitment

• Evaluation principles :

� Confidentiality and fair competition� Two-step approach :

1 –Technical evaluation 2 – Financial evaluation







� Main types of contract (1/2):

• Standard Service or Supply contracts :

� Deliverables-based (versus efforts-based)

� Fixed Price (or Lump-sum) for each Deliverable and/or Work Package

� Possibility to implement Works Instructions process when Work Packages

� Baseline, optional and conditional Work Packages

• Framework Service or Supply contracts :

� A contract that establishes terms and conditions under which subsequent

Task Orders will be placed

� Could be awarded to one or several contractors to enable min-

competition for each Task Order

� A Task Order can be :

• composed of quantities and applicable unit prices • based on IO technical specification and Contractor’s proposal







� Main types of contract (2/2):

• Strategic Agreement (catalogue of products):

� Contractual document signed between the IO and Supplier(s)which sets the terms and conditions under which anyDomestic Agency or their contractors may procure identifiedsupplies

� Concluded and signed by the IO to ensure standardization ofsupplies for the ITER Project






• IO will handle his responsibilities as:

� Designer for all TCWS scope � Manufacturer for Piping Procurement (with regards to the French

Order Feb.2012)

• Hence the IO will : � Lead the design activities and perform “in-house” part of the

design� Lead and coordinate the manufacturing and pre-assembly

operations

• IO will place Services and Supply contracts as follows:

� 7 Engineering Support Service Contracts for Design� 7 Manufacturing and Pre-Assembly Supply Contracts for Piping

Procurement� 2 Notified Body Services Contracts for Design and

Procurement


5.2 - TCWS General Contractual Strategy





� Contemplated selection process in most of the cases:

� Call for Tender with Call For Nomination and Pre-Qualification

� Award criteria based on Lowest Price Technically Compliant approach where the Technical Compliancy for each Requirement is to be justified in the Tender.


5.2 - TCWS General Contractual Strategy (cont’)





5.3 - TCWS Contractual Strategy for Design

No Scope of Work CFT Ref.

TCWS/FD/1Contract for Thermo-Hydraulic Analyses and Calculations for Process and System Engineering of TCWS

IO/14/CFN/9561A/TKA -TCWS/FD/1

PQ under final assessment

TCWS/FD/2Contract for Mechanical Analyses and Calculations of TCWS piping

IO/14/CFN/9561A/TKA -TCWS/FD/1

PQ under final assessment

TCWS/FD/3Contract for Analyses and Calculations for Mechanical Engineering of Equipment Design

Cancelled

TCWS/FD/4 Contract for Feasibility Studies CFN not issued

TCWS/FD/5 Optional : Contract for 2D-3D drawings CFN not issued

TCWS/FD/6 Contract I&C Engineering CFN not issued

TCWS/FD/7Contract for Agreed Notified Body Services during Final Design

Cancelled

TCWS/FD/8 Final Design for TCWS: 1st plasma equipment CFN not issued

TCWS/FD/9 Final Design for TCWS: 2nd plasma equipment CFN not issued

� “Deliverables-based” contracts (versus “effort-based”)

� For most of them, Contract Type will be :

�Contract with Fixed Price Work Packages and Works Instruction, or

�Framework Contracts with “mini-competition” and Tasks Orders.






� Each Contract will cover the needs of TCWS and potentially other ITER

Systems needs => Centralized Piping Procurement approach – See next slide

� For most of them, Contract Type will be : • Framework Contract or Strategic Agreement with Materials / Works

Catalogue and Unit Prices, with commitment on minimum quantities if possible

No Scope of Work CFT Ref.

TCWS/CP/1 Contract for procurement of piping and fittingsIO/14/CFT/9560/ACS

CFN to be closed by the 20/10/14

TCWS/CP/2 Contract for procurement of commercial supportsCFN not issued

TCWS/CP/3Contract for procurement of manual, motorized, safety and control valves & valve actuators

CFN not issued

TCWS/CP/4 Contract for procurement of instruments CFN not issued

TCWS/CP/5 Contract for procurement of miscellaneous CFN not issued

TCWS/CP/6 Contract for pre-assembly of piping CFN not issued

TCWS/CP/7 Contract for insulation of piping system and equipment CFN not issued


5.4 - TCWS Contractual Strategy for Procurement





� Specific Provisions : IO aims at making as wider as possible the range of

companies participating to the call for tender processes with regards to the

Contracts to be placed.

• Resulting Provision #1 : Capability versus proven experience in the

nuclear industry

⇒ A proven experience in the nuclear industry will not be required at the

Pre-Qualification stage but a capability to comply with some particular

requirements will be preferred. Also, to justify this capability,

subcontracting strategies will be accepted at the PQ and subcontractors will have to be declared at the CFT stage.

• Resulting Provision #2 : Transcribing French regulations into Requirements

⇒ IO is responsible as “Manufacturer” and will clearly specify in the technical

specifications for the Tenderers the particular technical and quality requirements involved by the application of the French applicable

regulations (French Order Feb 2012, ESP, ESPN)


5.4 TCWS Contractual Strategy for Procurement





5.5 - Centralized Piping opportunity for Procurement� Approach :

� Seven Framework Contracts will be placed for TCWS needs and are opened for other ITER Systems needs (from IO or DAs)

� Expected benefits for TCWS and other ITER Systems :

� Volume discount and cost savings � Optimizing contract management

� Simplification of final assembly by pre-assembled spools in timely

manner

� Standardization of technical specifications and final piping materials

� Other IO Systems already identified :

� Vacuum

� Atmosphere Detritiation System (ADS)� Part of CCWS and CHWS

� Tentative volume for piping :

TCWS Other PBSs Total Variation

30 45 75 x 2.5Piping needs in km

� Test Blanket Modules (TBM)

� Diagnostic Systems (DS)� Type A Radwaste System






� Regulatory requirement to have two separate contracts, but could be awarded to one single Contractor

� Each Contract will cover the needs of TCWS and potentially ITER Systems needs with regards to the Centralized Piping Procurement approach

� For these two contracts : �Contract Type should be Framework Contract with Tasks Orders. �Selection process should be Restricted Solicitation to companies

agreed Notified Body by ASN (French Nuclear Safety Authority)

No Scope of Work

TCWS/NB/1 Contract for Technical assistance in the field of Pressure Equipment and Nuclear Pressure Equipment.

TCWS/NB/2Contract for mission of Notified Body and Agreed Notified Body for the manufacture of several Pressure and Nuclear Pressure Equipment


5.6 - TCWS Contractual Strategy for Notified Body





No Scope of Work

TCWS/CP/1Contract for procurement of piping and

fittings

TCWS/CP/2Contract for procurement of commercial

supports

TCWS/CP/3

Contract for procurement of manual,

motorized, safety and control valves &

valve actuators

TCWS/CP/4 Contract for procurement of instruments

TCWS/CP/5Contract for procurement of

miscellaneous

TCWS/CP/6 Contract for pre-assembly of piping

TCWS/CP/7Contract for insulation of piping system

and equipment

TCWS Final Design Centralized Procurement and Pre-

Assembly of Pipes

NO

NO

Conflict of

interest with CP

YES

TCWS/NB/2

Contract for mission of Notified Body and Agreed Notified

Body for the manufacture of several Pressure and Nuclear

Pressure Equipment

NO

Nota : � No conflict of interest between CP contracts stated in CP/1 CFN (issued)� No conflict of interest between FD contracts stated in FD/1 and 2 CFN

(issued)

No Scope of Work

TCWS/FD/1

Contract for Thermo-Hydraulic Analyses and

Calculations for Process and System

Engineering of TCWS

TCWS/FD/2Contract for Mechanical Analyses and

Calculations of TCWS piping

TCWS/FD/3Contract for Analyses and Calculations for

Mechanical Engineering of Equipment Design

TCWS/FD/4 Contract for Feasibility Studies

TCWS/FD/6 Contract I&C Engineering

TCWS/FD/7Contract for Agreed Notified Body Services during

Final Design

TCWS/FD/8 Final Design for TCWS: 1st plasma equipment

TCWS/FD/9 Final Design for TCWS: 2nd plasma equipment

YES

YES*

YES*

TCWS/FD/5 Optional : Contract for 2D-3D drawings

TCWS/NB/1Contract for Technical assistance in the field of Pressure

Equipment and Nuclear Pressure Equipment.

5.7 - TCWS Contracts Mapping and Conflict of Interest

YES* Conflict with only one CP/X contract

[FD/4 with CP/6 and FD/6 with CP/4]

TCWS Notified Body

NO






5.7 - TCWS Contracts mapping and Conflict of Interest


� In summary:

• No conflict between:

� Design Contracts

� Procurement Contracts

� Notified Body Contracts

� FD/1, FD/5, FD/8, FD/9 and Procurement Contracts

• Conflict between :

� FD/2 (Piping mechanical analysis) and all Procurement Contracts

� FD/4 (Feasibility studies) and CP/6 (Piping pre-assembly)

� FD/6 (I&C engineering) and CP/4 (Instruments procurement)

� Notified Body Contracts and all Procurement Contracts






5.8 - TCWS & Centralized Piping Contracting Program

� Design contracts

S1 S2 S1 S2 S1 S2

CFT

CFT

CFT

CFT

CFT

CFT

2014 2015 2016

CFT

TCWS/FD/4

Thermo-Hydraulic Analyses and

Calculations for Process and System

Engineering of TCWS

Mechanical Analyses and Calculations

of TCWS piping TCWS/FD/2

No Scope of Work

Feasibility Studies

TCWS/FD/6

Optional 2D-3D drawingsTCWS/FD/5

TCWS/FD/1

I&C Engineering

TCWS/FD/9

TCWS/FD/8

Final Design for TCWS: 2nd

plasma

equipment

Final Design for TCWS: 1st plasma

equipment






� Procurement contracts


S1 S2 S1 S2 S1 S2

CFT

CFT

CFT

CFT

CFT

CFT

2014 2015 2016

CFT

Contract for insulation of piping

system and equipment TCWS/CP/7

TCWS/CP/5

TCWS/CP/6

Contract for procurement of manual,

motorized, safety and control valves &

valve actuators

TCWS/CP/3

Contract for procurement of

instrumentsTCWS/CP/4

No Scope of Work


commercial supports


miscellaneous

Pre-assembly of TCWS piping

TCWS/CP/2

Contract for procurement of piping and

fittingsTCWS/CP/1






� ANB contracts


S1 S2 S1 S2 S1 S2

CFTTCWS/NB/2

Contract for mission of Notified Body

and Agreed Notified Body for the

manufacture of several Pressure and

Nuclear Pressure Equipment

CFT

No Scope of Work2014 2015 2016

TCWS/NB/1

Contract for Agreed Notified Body

services during procurement and

construction
















10 - Conclusion – 16:00 / 16:15

16:30 / 17:30 : Site visit







6 – Focus on Design contracts

Prashant SINGH –IO/DIP/PSE/PED – TCWS Project Engineer





6 – Focus on Design contracts FD/1 : Contract for Thermo-Hydraulic Analyses and Calculations for Process and System Engineering of TCWS

Subject : Thermo-Hydraulic Analyses and Calculations for Process and System Engineering of TCWS

Main tasks / activities :

� Task 1: Thermo-hydraulic steady state analyses

� Task 2 : Thermo-hydraulic transient analyses

� Task 3 : Components sizing calculations

� Task 4 : Water Hammer analyses

� Task 5 : Design of overpressure protection systems

� Task 6 : Listing needed modifications to PFD and P&IDs

Particular skills:

� Experience in thermal-hydraulic design of nuclear systems or complex processing plants cooled by pressurised water.

� Computational analyses performed with Fathom and Arrow (or similar codes) for steady state analyses and Relap5 code for transient analyses. Experience in water hammer analyses.

� Experience in the design of overpressure protection systems.

� Knowledge of the requirements included in ESP/ESPN regulations.

Contract type : Fixed Prices Contract with Work Packages or Framework Contract

Duration forecast : 3 years

Key sizing figures :

� Thermo-hydraulic analyses and components sizing (Task1-2-3) for 5 TCWS sub-systems (excluding IBED and VV PHTS).

� Water hammer analyses and over pressure protection system design for 7 TCWS sub-systems (including IBED and VV PHTS).

� 115 reports to be produced.

Conflict : No





6 – Focus on Design contracts FD/2 : Contract for Mechanical Analyses and Calculations of TCWS piping

Subject : Mechanical Analyses and Calculations of TCWS piping


� Static and Dynamic stress analysis for Nuclear and Non – Nuclear class piping

� Postulation of Double End Guillotine Breaks for High Energy Lines, analysis of consequences and implementation of mitigating measures to cope with jet and whipping effect

� Detailed Design of Pipes and component supports and structures

� Thermal stratification studies and thermal fatigue analyses

Particular skills:

� Strong experience in the thermo mechanical analyses of nuclear piping

� Good knowledge of ASME B31.3 code and additional requirements of ESPN regulation

� Good knowledge of the Double End Guillotine Break problem and the associated effects

� Strong capacity to design a large amount of nuclear qualified supports and associated reports and drawings within a tight schedule

� Knowledge of Nuclear supports design codes, in particular AISC N690 / ASME III NF

� Proven capability to analyze the thermal stratification problem in piping systems




� 3400 process lines grouped in 150 Engineering Problems for Stress analyses

� 6500 individual supports to be designed and 6500 drawings to be produced

� 1200 potential rupture DEGB locations

� 3 pressurizer lines and potentially several more lines to be address for thermal fatigue

� 100 Reports to be produced, 300 Deliverables (including software files) ;30 Work Packages

Conflict : With all Piping Procurement Contracts






FD/4 : Contract for Feasibility Studies

Subject : Feasibility Studies


� General assessment of the present TCWS design solutions namely for the piping supporting systems and penetrations

� Study of design solutions for TCWS piping modularity and relevant prefabrication and assembly sequences

� Detailed Engineering analysis of the feasibility of the complex piping modules/skids in term of weldability, inspectability and maintenability

� Assessment of specific fabrication processes for double wall pipes’ spools

� FMECA analysis relevant to specific welded piping modules

Particular skills:

� Good knowledge of Nuclear piping manufacturing procedures

� Proven experience in prefabrication and modularization of Nuclear piping

� Extensive knowledge of Welding and NDE techniques

� Experience in FMECA analyses


Duration forecast : 7-9 months


� 7 different types of penetration configuration (In total 188 grouped penetrations)

� 43 potential pipe modules to be analyzed

� Approximately 1000 meters of double wall pipes

� 3500 Process lines

Conflict : With CP/6 pre-assembly of TCWS piping






FD/5 : Contract for 2D-3D drawings

Subject : Preparation of 2D Drawings – 3D models


� Convert Catia ® models to AVEVA PDMS ® models and vice versa

� Generation of Piping lay outs and GA drawings

� Generation of isometric drawings for piping construction

� Preparation of 3D models files for other contractors

Particular skills: � CAD – 2D/3D drawings


Duration forecast : 6 -9 months


� 3400 isometrics

� 150 3D models

� Approximately 150 – 200 2D Drawings

Conflict : No

OPTIONAL AS PER FUTURE IO NEEDS






FD/6 : Contract I&C Engineering

Subject : Instrumentation, Control & Electrical contract for Tokamak Cooling Water System of ITER


� Instrumentation engineering documents including function analysis, control logic, Instrument list, Instrument specification, etc…

� I&C architectural documents, Controllers configuration, Control Network configuration and so on

� Instrumentation installation drawings of control system to including instrument hook-up drawing,

Instrument loop drawings, cabling (electrical & Pneumatic) diagrams, and cubicle fabrication drawings

� Interface engineering for Instrument and Electrical systems

� Control Software Philosophy

� Electrical power engineering documents including load list revisions, single-line diagrams, power distribution equipment lists and specifications, etc….

� Electrical power distribution installation drawings including cable specification and diagrams, motor control centre (MCC/VFD) fabrication drawings, etc….

Particular skills: Instrumentation engineering for industrial plants, preferably water treatment systems or chemical plants. Experience in instrumentation installed in ionizing radiation and magnetic field, nuclear domain will be an added advantage


Duration forecast : 1 – 1,5 year


� > 3000 components

� > 10.000 Inputs/outputs

� > 50 MW

Conflict : With CP/4 : Contract for procurement of instruments






FD/8 : Final Design for TCWS: 1st plasma equipment

Subject : Final Design for TCWS: 1st plasma equipment


� Perform equipment associated calculations to support USDA and IO in the preparation of the component detailed design (Pressure Vessels, Heat Exchangers, Filters, Cyclones, Heaters, etc)

� Providing support to the USDA and IO during the preparation of the system’s 1st Plasma main component Technical Specification

� Providing expert support to the USDA and IO during the elaboration of the system’s 1st Plasma main components data sheets

� Providing support to the USDA and IO during the selection of 1st Plasma component supplier by giving expert advice on relevant technical issues

Particular skills: Systems engineering

Contract type : Framework Contract



� 3 Compressors and 11 pumps

� 10 Heat exchangers and 4 electrical heaters

� 6 Pressure vessels and 3 separators

� 4 cartridge filters

Conflict : Potential conflict with the contracts for Supply of components under USDA scope






FD/9 : Final Design for TCWS: 2nd plasma equipment

Subject : Final Design for TCWS: D - T plasma phase equipment


� Perform equipment associated calculations to support USDA and IO in the preparation of the component detailed design (Pressure Vessels, Heat Exchangers, Filters, Cyclones, Heaters, etc)

� Providing support to the USDA and IO during the preparation of the system’s D -T phase main component Technical Specification

� Providing expert support to the USDA and IO during the elaboration of the system’s D -T phase main components data sheets

� Providing support to the USDA and IO during the selection of D -T phase component supplier by giving expert advice on relevant technical issues

Particular skills: Systems engineering

Contract type : Framework Contract



� 20 pumps.

� 22 Heat exchangers and 3 electrical heaters.

� 17 Pressure vessels

� 14 cartridge filters and 4 mixed bed filters

Conflict : Potential conflict with the contracts for Supply of components under USDA scope
















10 - Conclusion – 16:00 / 16:15

16:30 / 17:30 : Site visit







7 – Focus on Procurement contracts

Moustafa MOTELEB –IO/DIP/PSE/PED – TCWS Project Manager






CP/1 : Contract for Procurement of Piping and Fittings

Subject : Manufacturing and procurement of Piping and Fittings for TCWS and other systems of ITER machine

Materials:

� Seamless Stainless Pipes

� Welded Stainless Pipes

� Welded Carbon Pipes

� Seamless and welded austenitic stainless steel butt welding fittings

� Austenitic stainless steel integrally reinforced forged branch outlet fittings

Particular Requirements : Applicable standards: ASTM for all, ESP and ESPN partially

Contract Type : Framework Contract or Strategic Agreement with Materials / Works Catalogue and Unit Prices


Key Sizing Figures :

� Stainless pipes : 60 ≤ X ≤ 100 km

� Carbon Pipe : X ≤ 5 km

� Fittings : 30 000 +/- 20% units

� Size (DN): 15 to 500






CP/1 : Contract for Procurement of Piping and Fittings

� Selection process progress status :

• CFN extended until October 20th following clarification sent to the DAs on the 29.09

• PQ should be launched by the end of October - CFT should be launched by December

� Pre-Qualification criteria will be based on the following approach :

• Proven experience in :

� manufacturing or procuring Seamless Stainless Pipes in conformity with ASTM A312 standard

• Capacity in :

� manufacturing or procuring other materials (Welded Stainless Pipes, Stainless Fittings, ….)

in compliance with relevant ASTM standards

� manufacturing or procuring Pipes and Fittings in compliance with some particular technical

requirements on chemical composition and mechanical properties (mainly involved by ESP/ESPN)

� Quality Assurance Management in compliance with particular quality requirements (mainly

involved by IO Quality System, ESP/ESP and French Order Feb. 2012)

� Supply Chain Management on large equipment manufacturing and procurement contracts

⇒ The demonstration can be based on subcontracting strategy. In such case, name(s) and capabilities of identified subcontractor(s) are required.






Subject : Commercial off the shelf (COTS) pipe supports

Materials:

� Springs (Variable, Constant, and Angulating)

� Rigid Sway Strut

� Snubbers (Hydraulic and Mechanical)

� Energy Absorber

� Pipe Clamp (Restraint, Dynamic, Two bolt, Three bolt)

� Riser Clamp

� Pipe Saddle

� Insulated Pipe Shoes

� Pipe Slides

� Pipe Whip Restraint

� Hanger Rod

� Turnbuckle

� U-Bolt

Particular requirements :� Applicable design standards: ASME B31.3 and MSS-SP-58

� Nuclear Qualification documentation and Design Record Sheets required

Contract type : Framework Contract or Strategic Agreement with Materials / Works Catalogue and Unit Prices



� Size (DN): 15 to 500

� Carbon Steel supports: approx. 5900 Supporting units

� Stainless steel supports: approx. 530 Supporting units

CP/2 : Contract for procurement of commercial supports






Subject : Manual, motorized, safety and control valves & valve actuators

Materials:

� Manual valves with ratings ranging from 150# to 900 #

� Pneumatic Actuators and Electric Motor including required accessories, spare parts and documentation to the IO

� Control valves including required accessories, spare parts and documentation to the IO

� Pilot operated relief valves and Spring operated relief valves

Particular requirements :

� Applicable Standards: ASME B16.34 (Valve Body), ASTM for all, ESP and ESPN partially, Machinery Directive (Control Valves and Actuators), and EMC Directive (Control Valves and Actuators)

� Seismic qualification required for most of the valves

� Most valves with rigorous leak tightness requirements

� Some valves with particularly low seat leakage requirements




� Valve Size (DN): 15 to 500

� Approximately 2700 valves (Manual, operated), 100 Relief Valves, 100 Control Valves, 2200 actuators (Pneumatic and Motor operated)

CP/3 : Contract for procurement of manual, motorized, safety and control valves & valve actuators






Subject : Piping instruments

Materials:

� Instrumentation relative to standard process variables (transmitters, indicators switches): Pressure / Temperature / Level / Flow

� Water analysis and monitoring : pH / Dissolved Oxygen / Dew point / Hydrogen sensors

� Radiation monitoring

� Signal/command processing : Signal conditioners /Pre-actuator (solenoid valves) / IO Remote Device

� Valves accessories : Positioners (modulating valves) /Position Switches

Particular requirements : Technical Specifications pending Final Design



Key sizing figures : TBD pending Final Design

CP/4 : Contract for procurement of instruments






Subject : Various Piping materials

Materials:

� Orifices

� Bellows

� Flanges

� Feed-throughs (for piping)


� For orifices and bellows a proper customization is needed to meet the TCWS needs and is described in the technical specification

� Applicable Standards: ASME B16.36 (Orifice Flange), ASME B31.3 (Bellows), ASME B16.5 (Flanges), and ASME B16.47 (Flanges)




� Size (DN): 15 to 500

� Approximately 120 cylindrical bellows and 18 big oblong bellows

� 400 orifice plates

� 300 flanges

CP/5 : Contract for procurement of miscellaneous






Subject : Pre-assembly and pre-testing of piping spools

Technical works : � Pre-fabrication and pre-testing of TCWS piping spools and skids

(Modular Units)


� Proximity of workshop to ITER site

� Capacity to manufacture modular skids weighing up to 20 tons

� Previous experience

� Financial capacity

� Bonding capacity



Key sizing figures : Size (DN): 15 to 500

CP/6 : Construction of TCWS piping






Subject : Insulation of piping system and equipment

Technical works : � Mineral wool (outside Cryostat) .

� Microtherm Super G or similar super-insulation (inside Cryostat)


� Lifetime: 20 years minimum (without maintenance)

� Chemical composition : - No halogens - S and F (%weight) = 0.025% maximum of each



Key sizing figures : Size (DN): 15 to 500

CP/7 : Contract for insulation of piping system and equipment
















10 - Conclusion – 16:00 / 16:15

16:30 / 17:30 : Site visit







8 - US DA Procurement program

Kirby Wilcher, TCWS Engineer, US ITER





Subject : Total TCWS Procurement Scope is shared between ITER IO (France) and US ITER (USA) US ITER Procurement originating from organization in USA:

• Pumps • Demineralizers • Compressors• Heat Exchangers • Dryers • Associated Electrical and I&C items• Tanks & Vessels • Filters

• Pressurizers • Degasifiers

8 - US DA Procurement Program





Subject : Manufacturing and Procurement of Rotating Equipment for

TCWS

Equipment:

� Main Cooling Water Pumps

� Transfer Pumps

� Chemical Injection Pumps & Skids

� Nitrogen Charging Compressor

� Drying Primary Compressor

Particular

Requirements :Applicable standards: Machinery Directive, API, ASME

Contract Type : Individual Fixed Unit Prices

Schedule : Contract Launch: 1st Procurement Cycle beginning 2016

Contract Duration: TBD for 1st and 2nd Procurement Cycles

Key Sizing Figures :

Quantity: Over (30) Major Equipment Tag Numbers

Stainless pumps: Size (DN): 60 to 500

Ranging from Small Transfer Pumps to

6 MW Main Pumps with flow rate: 1.2 m3/s (over 1,000 kg/s),

3.77 MPa Head






Subject : Manufacturing and Procurement of Passive Equipment for TCWS

Equipment:

� Pressurizers

� Pressure Relief Tanks� Main Cooling Water Heat Exchangers� Decay Heat Exchanger

� Volume Control, Letdown and Regenerative Heat Exchangers

� Auxiliary & Waste Drain Tank, Volume Control Tanks

� Demineralizers, Condensers

� Filters, Degasifiers, and Moisture SeparatorsParticular Requirements :

Applicable standards: ESPN, PED, ASME

Contract Type : Individual Fixed Unit Prices

Schedule : Contract Launch: 1st Procurement Cycle beginning 2016

Contract Duration: TBD for 1st and 2nd Procurement Cycles

Key Sizing Figures : Quantity: Approximately (100) Major Equipment Tag Numbers Stainless steel pressure vessels: volume ranges from low

volume filter housings, to pressurizer over 50 cubic meter

Page 60






TCWS Procurement Schedule: Captive Piping / 1st Plasma Equipment






TCWS Procurement Schedule: 2nd Plasma Equipment






Subject : Point of Contacts (POC) for Manufacturing and Procurement of

Equipment for TCWS

CAMs: May be contacted now for participation in budgetary engineering

cost estimates.

� Fabrication Manager: Jay Brizendine [email protected](all items)

� Draining: Juan Ferrada [email protected]

� VV PHTS: Andrei Petrov [email protected]

� Drying: Juan Ferrada [email protected]

� CVCS: Andrei Petrov [email protected]

� IBED PHTS: Kirby Wilcher [email protected]

� NBI PHTS: Andrei Petrov [email protected]

Page 63

















10 - Conclusion – 16:00 / 16:15

16:30 / 17:30 : Site visit







9 – Questions / Answers





9 - Questions / Answers
















10 - Conclusion – 16:00 / 16:15

16:30 / 17:30 : Site visit





Tokamak Cooling Water Systems

(TCWS) Design and Centralized Procurement for ITER Piping

10 – Conclusion

Sergio ORLANDI – IO/DIP/Director of Directorate for Plant System Engineering (PSE) and Chief Executive Engineer





� IO is looking for suppliers or consortia who can

comply with Tokamak Cooling Water Systems

(TCWS) Design and Centralized Procurement for

ITER Piping specifications, including:

• Technical requirements,

• Schedule requirements,

• Quality/Safety requirements,

• Conflict of interest/unfair technical advantage requirements.

10 – Conclusion





� Successful Tenderers will demonstrate:

10 – Conclusion

• A thorough understanding of what is being asked

• A well-thought out technical solution

• A high degree of confidence that the requirements will be met

• A high level of professionalism in QA matters

• An adequate level of resources to achieve on time

• A reasonable/competitive price





� ITER Organization is looking for a collaborative

approach in the forthcoming contracts:

• IO needs to work with “Suppliers” or “Performers” who will

take responsibility in the contract execution with a shared

approach with the IO, of the identified risks;

• IO is determined to use “Suppliers” or “Performers” who

have the capacity to identify in advance difficulties or

uncertainties in order to smoothly address them in a

collaborative manner.

10 – Conclusion





Industry Feedback

� All attendees are kindly invited:

• to fill-in the Questionnaire available from today onthe ITER PCD web portal :

http://www.iter.org/org/team/adm/proc/overview

• to send it back to the following e-mail address no laterthan October 21st 2014, at :

[email protected]

10 – Conclusion

� Read more on the IO Procurement Web Site:

http://www.iter.org/org/team/adm/proc/generalinfo

� TCWS Procurement officer :

[email protected]





Tokamak Cooling Water Systems

(TCWS) Design and Centralized Procurement for ITER Piping

Site Visit

16:30 – 17:30

tokamak cooling water systems (tcws) design and ... to a supporting welding procedure specification...

Documents